Additives to silane for thin film silicon photovoltaic devices

ABSTRACT

Chemical additives are used to increase the rate of deposition for the amorphous silicon film (αSi:H) and/or the microcrystalline silicon film (μCSi:H). The electrical current is improved to generate solar grade films as photoconductive films used in the manufacturing of Thin Film based Photovoltaic (TFPV) devices.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OF DEVELOPMENT

This invention was made at least in part with funding with the United States Department of Energy under DOE Cooperative Agreement No. DE-EE0000580. The United States Government has certain rights in this invention.

BACKGROUND OF THE INVENTION

Photovoltaic devices (PV) or solar cells are devices which convert sunlight into direct current (DC) electrical power.

Thin Film based Photovoltaic (TFPV) devices have been using both amorphous silicon film (αSi:H) and microcrystalline silicon film (μCSi:H) for low cost thin film photovoltaic devices. Hydrogenated amorphous silicon (αSi:H) has been studied for applications in solar cells for several decades. More recently, microcrystalline silicon (μCSi:H) has been studied because it is a suitable material for the intrinsic layer in the bottom cell of thin-film tandem solar cells.

The deposition of αSi:H and μCSi:H on large substrate based photovoltaic (PV) panels has been accomplished primarily using silane (SiH₄) and hydrogen gases (H₂) mixtures. The work have been done in the field includes: US2009/0077805 A1, US2007/0298590 A1), U.S. Pat. No. 6,855,621 B2 and JP2005244037. A. Hammad et al (Thin Solid Films 451-452 (2004) 255-258) studied the hydrogenated microcrystalline silicon thin films using silane (SiH₄), hydrogen gases (H₂) and disilane (Si₂H₆).

However, the deposition processes are relatively slow (5 Å/sec for αSi:H and 1-7 Å/sec for μCSi:H) creating a bottle neck in the manufacturing of TFPV panels. This leads to a lower process tool through-put, which in turn leads to higher cost per Watt for the manufactured panels.

Additionally, deposition of αSi:H and μCSi:H on large substrate based photovoltaic (PV) panels with the existing chemistry of SiH₄ and H₂ yield solar cells with effiClenCles ranging from 6% to 10%, depending, on cell design. The cell effiClency is dependent upon the quality of the αSi:H and μCSi:H deposited, and more speClfically related to the grain size of crystallites in μCSi:H, number of defects and donor impurities present in the film.

Therefore, there is a need of a method for depositing an amorphous silicon film (αSi:H) and a microcrystalline silicon film (μCSi:H) with increased deposition rate and increased cell effiClency.

BRIEF SUMMARY OF THE INVENTION

Accordingly, the present invention is directed to the use of chemical additives to increase the rate of deposition processes, and improve the electrical current generating capability of the deposited films for photoconductive films used in the manufacturing of Thin Film based Photovoltaic (TFPV) devices.

In one embodiment, the invention provides a method of deposition for a solar grade amorphous silicon film (αSi:H) as a photoconductive film on a substrate, using

-   -   Silane;     -   hydrogen; and     -   at least one additive selected from the group consisting of:         -   (a) higher order straight chain silanes, comprising;             disilane Si₂H₆, trisilane Si₃H₈, tetrasilane Si₄H₁₀,             pentasilane Si₅H₁₂, hexasilane Si₆H₁₄, heptasilane Si₇H₁₆,             octasilane Si₈H₁₈, nonasilane Si₉H₂₀, decasilane Si₁₀H₂₂ and             mixtures thereof;         -   (b) higher order branched silanes, comprising;             2-silyl-trisilane SiH₃—Si(H)(SiH₃)—SiH₃,             2,2-disilyl-trisilane SiH₃—Si(SiH₃)₂—SiH₃,             2-silyl-tetrasilane SiH₃—Si(H)(SiH₃)—SiH₂—SiH₃,             2,3-disilyltetrasilane SiH₃—SiH(SiH₃)—SiH(SiH₃) —SiH₃,             2,2-disilyltetrasilane SiH₃—Si(SiH₃)₂—SiH₂—SiH₃,             3-silylpentasilane SiH₃—SiH₂—SiH(SiH₃)—SiH₂—SiH₃,             2-silylpentasilane SiH₃—SiH(SiH₃)—SiH₂—SiH₂—SiH₃,             2,3-disilylpentasilane SiH₃—SiH(SiH₃)—SiH(SiH₃)—SiH₂—SiH₃,             2,4-disilylpentasilane SiH₃—SiH(SiH₃)—SiH₂—SiH(SiH₃)—SiH₃,             2-silylhexasilane SiH₃—SiH(SiH₃)—(SiH₂)₃SiH₃,             3-silylhexasilane SiH₃—SiH₂—SiH(SiH₃)—(SIH₂)₂SiH₃,             2,2-disilylpentasilane SiH₃—Si(SiH₃)₂—(SiH₂)₂—SiH₃,             3,3-disilylpentasilane             SiH₃—SiH₂—Si(SiH₃)₂SiH₂SiH₃2,2,3-trisilyltetrasilane             SiH₃—Si(SiH₃)₂—SiH(SiH₃)—SiH₃, 2-silylheptasilane             SiH₃—SiH(SiH₃)—(SiH₂)₄—SiH₃, 3-silylheptasilane             SiH₃—SiH₂—SiH(SiH₃)—(SiH₂)₃—SiH₃, 4-silylheptasilane             SiH₃—(SiH₂)₂—SiH(SiH₃)—(SiH₂)₂—SiH₃, 2,2-disilylhexasilane             SiH₃—Si(SiH₃)₂—(SiH₂)₃—SiH₃, 2,3-disilylhexasilane             SiH₃—SiH(SiH₃) —SiH(SiH₃)—(SiH₂)₂—SiH₃,             2,4-disilylhexasilane             SiH₃—SiH(SiH₃)—SiH₂—SiH(SiH₃)—SiH₂—SiH₃,             2,5-disilylhexasilane SiH₃—SiH(SiH₃)—(SiH₂)₂—SiH(SiH₃)—SiH₃,             3,3-disilylhexasilane SiH₃—SiH₂—Si(SiH₃)₂—(SiH₂)₂—SiH₃, 3,4-             disilylhexasilane SiH₃—SiH₂—SiH(SiH₃)—SiH(SiH₃)—SiH₂—SiH₃,             2,2,3-trisilylpentasilane             SiH₃—Si(SiH₃)₂—SiH(SiH₃)—SiH₂—SiH₃,             2,2,4-trisilylpentasilane             SiH₃—Si(SiH₃)₂—SiH₂—SiH(SiH₃)—SiH₃,             2,3,3-trisilylpentasilane             SiH₃—SiH(SiH₃)—Si(SiH₃)₂—SiH₂—SiH₃,             2,3,4-trisilylpentasilane             SiH₃—SiH(SiH₃)—SiH(SiH₃)—SiH(SiH₃)—SiH₃,             2,2,3,3-tetrasilyltetrasilane SiH₃—Si(SiH₃)₂—Si(SiH₃)₂—SiH₃             and mixtures thereof;         -   (c) cyclic silanes, selected from the group consisting of;             cyclotrisilane Si₃H₆, cyclotetrasilane Si₄H₈,             cyclopentasilane Si₅H₁₀, cyclohexasilane Si₆H₁₀, and             mixtures thereof;         -   (d) silyl substituted cyclic silanes, selected from the             group consisting of; silyl cyclotetrasilane SiH3—Si₄H₇,             1,2-disilylcyclopentasilane (SiH₃)₂—Si₅H₈, silyl             cyclohexasilane SiH₃—Si₆H₁₁, 1,3-disilyl cyclohexasilane             (SiH₃)₂—Si₆H₁₀, and mixtures thereof;         -   (e) silyl substituted silanes, selected from the group             consisting of; 2-tetrasilane SiH₃—SiH═SiH—SiH₃,             2,3-disilyltetrasil-2-ene SiH₃-Si(SiH₃)═Si(SiH₃)—SiH₃,             2,3-disilylpentasil-2-ene SiH₃—Si(SiH₃)═Si(SiH₃)—SiH₂—SiH₃,             2,5-disilylhexasil-2-ene             SiH₃—Si(SiH₃)═SiH—SiH2—SiH(SiH₃)—SiH₃,             2,3,4-trisilylhexasil-2-ene             SiH₃—Si(SiH₃)═Si(SiH₃)—SiH(SiH₃)—SiH₂—SiH₃, and mixtures             thereof;         -   (f) halogen substituted silanes, including;             1,1-dichlordisilane SiHCl₂SiH₃, 1,1,1,2-tetrafluorodislane             SiF₃—SiH₂F, 1,2-dichloro-1,2-difluorotetrasilane             SiHClF—SiClF—SiH₂—SiH₃, 1,1,1-trichlorotrisilane             SiCl₃—SiH₂—SiH₃, 1,1-difluoro-1,2,2-trichlorosilane             SiF₂Cl—SiCl₂—SiH₃, chloropentasilane SiH₂Cl—(SiH₂)₃—SiH₃,             and other compounds of the general formula             Si_(w)H_(2w+2−z)X_(z)where X═F, Cl, Br, I; w can be 1 to 20             and z can be 1 to 2w+2; 2-chlorotetrasil-2-ene             SiH₃—SiCl═SiH—SiH₃, 1,1-dichloro-2-fluoropentasil-2-ene             SiHCl₂—SiF═SiH₂—SiH₂—SiH₃, 2,3-dichlorotetrasil-2-ene             SiH₃—SiCl═SiCl—SiH₃, and other compounds of the general             formula Si_(w)H_(2w-z)X′_(z) where X′═F, Cl, Br, I; and, w             can be 2 to 20 and z can be 1 to 2w; and mixtures thereof;             and         -   (g) halogen substituted cyclic silanes, selected from the             group consisting of; chlorocyclopentasilane Si₅H₉Cl,             dodecachlorocyclohexasilane Si₆Cl₁₂,             1-chloro-1fluorocyclopentasilane Si₅H₈FCl, and mixtures             thereof;         -   and the deposited solar grade amorphous silicon film (αSi:H)             thereof.

In another embodiment, the invention provides a method of deposition for amorphous silicon film (αSi:H) or microcrystalline silicon film (μCSi:H) as a photoconductive film on a substrate, using

-   -   Silane;     -   hydrogen;     -   at least one additive selected from the group consisting of:         -   (a) higher order straight chain silanes, comprising;             disilane Si₂H₆, trisilane Si₃H₈, tetrasilane Si₄H₁₀,             pentasilane Si₅H₁₂, hexasilane Si₆H₁₄, heptasilane Si₇H₁₆,             octasilane Si₈H₁₈, nonasilane Si₉H₂₀, decasilane Si₁₀H₂₂ and             mixtures thereof;         -   (b) higher order branched silanes, comprising;             2-silyl-trisilane SiH₃—Si(H)(SiH₃)—SiH₃,             2,2-disilyl-trisilane SiH₃—Si(SiH₃)₂—SiH₃,             2-silyl-tetrasilane SiH₃—Si(H)(SiH₃)—SiH₂—SiH₃,             2,3-disilyltetrasilane SiH₃—SiH(SiH₃)—SiH(SiH₃)—SiH₃,             2,2-disilyltetrasilane SiH₃—Si(SiH₃)₂—SiH₂—SiH₃,             3-silylpentasilane SiH₃—SiH₂—SiH(SiH₃)—SiH₂—SiH₃,             2-silylpentasilane SiH₃—SiH(SiH₃)—SiH₂—SiH₂—SiH₃,             2,3-disilylpentasilane SiH₃—SiH(SiH₃)—SiH(SiH₃)—SiH₂—SiH₃,             2,4-disilylpentasilane SiH₃—SiH(SiH₃)—SiH₂—SiH(SiH₃)—SiH₃,             2-silylhexasilane SiH₃—SiH(SiH₃)—(SiH₂)₃SiH₃,             3-silylhexasilane SiH₃—SiH₂—SiH(SiH₃)—(SiH₂)₂SiH₃,             2,2-disilylpentasilane             SiH₃—Si(SiH₃)₂—(SiH₂)₂—SiH₃,3,3-disilylpentasilane             SiH₃—SiH₂—Si (SiH₃)₂—SiH₂—SiH₃, 2,2,3-trisilyltetrasilane             SiH₃—Si(SiH₃)₂—SiH(SiH₃)—SiH₃, 2-silylheptasilane             SiH₃—SiH(SiH₃)—(SiH₂)₄—SiH₃, 3-silylheptasilane             SiH₃—SiH₂—SiH(SiH₃)—(SiH₂)₃—SiH₃, 4-silylheptasilane             SiH₃—(SiH₂)₂—SiH(SiH₃)—(SiH₂)₂—SiH₃, 2,2-disilylhexasilane             SiH₃—Si(SiH₃)₂—(SiH₂)₃—SiH₃, 2,3-disilylhexasilane             SiH₃—SiH(SiH₃) —SiH(SiH₃)—(SiH₂)₂—SiH₃,             2,4-disilylhexasilane             SiH₃—SiH(SiH₃)—SiH₂—SiH(SiH₃)—SiH₂—SiH₃,             2,5-disilylhexasilane SiH₃—SiH(SiH₃)—(SiH₂)₂—SiH(SiH₃)—SiH₃,             3,3-disilylhexasilane SiH₃—SiH₂—Si(SiH₃)₂—(SiH₂)₂—SiH₃,             3,4-disilylhexasilane             SiH₃—SiH₂—SiH(SiH₃)—SiH(SiH₃)—SiH₂—SiH₃,             2,2,3-trisilylpentasilane             SiH₃—Si(SiH₃)₂—SiH(SiH₃)—SiH₂—SiH₃,             2,2,4-trisilylpentasilane             SiH₃—Si(SiH₃)₂—SiH₂—SiH(SiH₃)—SiH₃,             2,3,3-trisilylpentasilane             SiH₃—SiH(SiH₃)—Si(SiH₃)₂—SiH₂—SiH₃,             2,3,4-trisilylpentasilane             SiH₃—SiH(SiH₃)—SiH(SiH₃)—SiH(SiH₃)—SiH₃,             2,2,3,3-tetrasilyltetrasilane SiH₃—Si(SiH₃)₂—Si(SiH₃)₂—SiH₃             and mixtures thereof;         -   (c) cyclic silanes, selected from the group consisting of;             cyclotrisilane Si₃H₆, cyclotetrasilane Si₄H₈,             cyclopentasilane Si₅H₁₀, cyclohexasilane Si₆H₁₀, and             mixtures thereof;         -   (d) silyl substituted cyclic silanes, selected from the             group consisting of; silyl cyclotetrasilane SiH3-Si₄H₇,             1,2-disilyl cyclopentasilane (SiH₃)₂—Si₅H₈, silyl             cyclohexasilane SiH₃—Si₆H₁₁, 1,3-disilyl cyclohexasilane             (SiH₃)₂—Si₆H₁₀, and mixtures thereof;         -   (e) silyl substituted silanes, selected from the group             consisting of; 2-tetrasilane SiH₃—SiH═SiH—SiH₃,             2,3-disilyltetrasil-2-ene SiH₃—Si(SiH₃)═Si(SiH₃)—SiH₃,             2,3-disilylpentasil-2-ene SiH₃—Si(SiH₃)═Si(SiH₃)—SiH₂—SiH₃,             2,5-disilylhexasil-2-ene             SiH₃—Si(SiH₃)═SiH-SiH2—SiH(SiH₃)—SiH₃,             2,3,4-trisilylhexasil-2-ene             SiH₃—Si(SiH₃)═Si(SiH₃)—SiH(SiH₃)—SiH₂—SiH₃, and mixtures             thereof;     -   and     -   at least one another additive selected from the group consisting         of:         -   (f) halogen substituted silanes, selected from the group             consisting of; monochlorosilane SiH₃Cl, dichlorosilane             SiH₂Cl₂, trichlorosilane SiHCl₃, tetrachlorosilane (SiCl₄),             chlorodisilane SiH₃—SiH₂Cl, and mixtures thereof; and         -   (g) halogen containing gases, selected from the group             consisting of; chlorine Cl₂, hydrogen chloride HCl, chlorine             trifluoride ClF₃, nitrogen trifluoride NF₃, fluorine F₂,             hydrogen fluoride HF, bromine Br₂, hydrogen bromide HBr,             hydrogen iodide HI and mixtures thereof;             and the deposited amorphous silicon film (αSi:H) or             microcrystalline silicon film (μCSi:H) thereof.

In yet another embodiment, the invention provides a method of deposition for a solar grade amorphous silicon film (αSi:H) or a microcrystalline silicon film (μCSi:H) having high microcrystalline fraction as a photoconductive film on a substrate, using

-   -   Silane;     -   hydrogen; and     -   at least one additive selected from the group consisting of:         -   (a) halogen substituted higher order silanes, including;             1,1-dichlordisilane SiHCl₂SiH₃, 1,1,1,2-tetrafluorodislane             SiF₃—SiH₂F, 1,2-dichloro-1,2-difluorotetrasilane             SiHClF—SiClF—SiH₂—SiH₃, 1,1,1-trichlorotrisilane             SiCl₃—SiH₂—SiH₃, 1,1-difluoro-1,2,2-trichlorosilane             SiF₂Cl-SiCl₂—SiH₃, chloropentasilane SiH₂Cl—(SiH₂)₃—SiH₃,             and other compounds of the general formula             Si_(w)H_(2w+2−z)X_(z) where X ═F, Cl, Br, I; w can be 1 to             20 and z can be 1 to 2w+2; 2-chlorotetrasil-2-ene             SiH₃—SiCl═SiH—Si H₃, 1,1-dichloro-2-fluoropentasil-2-ene             SiHCl₂—SiF═SiH₂—SiH₂—SiH₃, 2,3-dichlorotetrasil-2-ene             SiH₃—SiCl═SiCl—SiH₃, and other compounds of the general             formula Si_(w)H_(2w-z)X′_(z) where X′═F, Cl, Br, I; and, w             can be 2 to 20 and z can be 1 to 2w; and mixtures thereof;             and         -   (b) halogen substituted cyclic higher order silanes,             selected from the group consisting of;             chlorocyclopentasilane Si₅H₉Cl, dodecachlorocyclohexasilane             Si₆Cl₁₂, 1-chloro-1fluorocyclopentasilane Si₅H₈FCl, and             mixtures thereof.             and the deposited solar grade amorphous silicon film (αSi:H)             or microcrystalline silicon film (μCSi:H) having high             microcrystalline fraction thereof.

The deposited films in the embodiments disclosed above, provide high deposition rates, enhanced photoconductivity, solar grade for amorphous silicon film (αSi:H), and high microcrystalline fraction for microcrystalline silicon film (μCSi:H).

BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS

FIG. 1. The Empirical Microstructure Factor R* of hydrogenated silicon αSi:H versus SiH₄ flow rate under different power densities. The hydrogenated silicon αSi:H was deposited using silane and hydrogen.

FIG. 2. The deposition rate of hydrogenated silicon αSi:H versus SiH₄ flow rate under different power densities. The hydrogenated silicon αSi:H was deposited using silane and hydrogen.

FIG. 3. The deposition rate of hydrogenated silicon αSi:H versus the flow rate of the mixture of SiH4 and disilane under different power densities. The hydrogenated silicon αSi:H was deposited using silane disilane and hydrogen.

FIG. 4. The Empirical Microstructure Factor R* of hydrogenated silicon αSi:H versus the flow rate of the mixture of SiH4 and disilane under different power densities. The hydrogenated silicon αSi:H was, deposited using silane, disilane and hydrogen.

FIG. 5. The microcrystalline fraction versus the mole fraction SiH₃Cl/(SiH₃Cl+Si_(x)H_(y)) %.

FIG. 6. The Activation Energy for deposited microcrystalline film versus the mole fractions of halogenated silanes SiH₃Cl/SiH₃Cl+Si_(x)H_(y)) (%).

DETAILED DESCRIPTION OF THE INVENTION

In prior arts, Plasma power, frequency, temperature, gas mixing ratios and pressure have been used to control film structure, thickness and electrical properties.

The present invention further discloses the use of chemical additives to increase the rate of deposition processes, and improve the electrical current generating capability of the deposited films for photoconductive films used in the manufacturing of Thin Film based Photovoltaic (TFPV) devices.

Increasing the module effiClency is one approach for reduClng manufacturing costs. The present invention discloses the reduction of manufacturing costs through the addition of additives to the mixture of SiH₄ and H₂.

In present invention, the additives are used to increase the deposition rate, and in addition, to control film structure to achieve the better grade for the practical use, to optimize crystalline grain sizes, reduce the number of defects and/or minimize or neutralize the effects of impurities present as a result of contamination, from the processing environment; thus to reduce manufacturing costs.

More speClfically, the present invention uses the mixture of silane and hydrogen as the primary source of silicon, and uses additives as the process enhanClng feature. The process enhancements are significantly greater than the potential additional cost afforded by the use of higher value additives. These enhancements lead to a lower cost per unit of energy through: (i) a faster deposition rate and better controlling of film grade resulting, from the addition of relatively low mole fractions of higher order silanes; and, (ii) more photoconductive film through the addition of a halogen containing gas or a halogen substituted silane containing gas.

The deposition processes include but not limited to Chemical Vapor Deposition (CVD), Plasma Enhanced Chemical Vapor Deposition (PECVD), Low Pressure Chemical Vapor Deposition (LPCVD), Hot Wire Chemical Vapor Deposition (HWCVD), Initiated Chemical Vapor Deposition (ICVD) and Sub Atmospheric Chemical Vapor Deposition (SA-CVD).

Process enhanClng additives include, but not limited to

(a) Higher order straight chain silanes, including; disilane Si₂H₆, trisilane Si₃H₈, tetrasilane Si₄H₁₀, pentasilane Si₅H₁₂, hexasilane Si₆H₁₄, heptasilane Si₇H₁₆, octasilane Si₈H₁₈, nonasilane Si₉H₂₀, decasilane Si₁₀H₂₂ and other straight chain silanes following the general formula Si_(x)H_(2x+2) where can be 2-20;

(b) Higher order branched silanes including; 2-silyl-trisilane SiH₃—Si(H)(SiH₃)—SiH₃, 2,2-disilyl-trisilane SiH₃—Si(SiH₃)₂—SiH₃, 2-silyl-tetrasilane SiH₃—Si(H)(SiH₃)—SiH₂—SiH₃, 2,3-disilyltetrasilane SiH₃—SiH(SiH₃)—SiH(SiH₃)—SiH₃,2,2-disilyltetrasilane SiH₃—Si(SiH₃)₂—SiH₂—SiH₃, 3-silylpentasilane SiH₃—SiH₂—SiH(SiH₃)—SiH₂—SiH₃,2-silylpentasilane SiH₃—SiH(SiH₃)—SiH₂—SiH₂—SiH₃ 2,3-disilylpentasilane SiH₃SiH(SiH₃)—SiH(SiH₃)—SiH₂—SiH₃, 2,4-disilylpentasilane SiH₃—SiH(SiH₃)—SiH₂—SiH(SiH₃)—SiH₃, 2-silylhexasilane SiH₃—SiH(SiH₃)—(SiH₂)₃SiH₃, 3-silylhexasilane SiH₃—SiH₂—SiH(SiH₃)—(SiH₂)₂SiH₃, 2,2-disilylpentasilane SiH₃—Si(SiH₃)₂—(SiH₂)₂—SiH₃, 3,3-disilylpentasilane SiH₃—SiH₂—Si(SiH₃)₂—SiH₂—SiH₃, 2,2,3-trisilyltetrasilane SiH₃—Si(SiH₃)₂—SiH(SiH₃)—SiH₃, 2-silylheptasilane SiH₃—SiH(SiH₃)—(SiH₂)₄—SiH₃, 3-silylheptasilane SiH₃—SiH₂—SiH(SiH₃)—(SiH₂)₃—SiH₃, 4-silylheptasilane SiH₃—(SiH₂)₂—SiH(SiH₃)—(SiH₂)₂—SiH₃, 2,2-disilylhexasilane SiH₃—Si(SiH₃)₂—(SiH₂)₃—SiH₃, 2,3-disilylhexasilane SiH₃—SiH(SiH₃)—SiH(SiH₃)—(SiH₂)₂—SiH₃, 2,4-disilylhexasilane SiH₃—SiH(SiH₃)—SiH₂—SiH(SiH₃)—SiH₂—SiH₃, 2,5-disilylhexasilane SiH₃—SiH(SiH₃)—(SiH₂)₂—SiH(SiH₃)—SiH₃, 3,3-disilylhexasilane SiH₃—SiH₂—Si(SiH₃)₂—(SiH₂)₂—SiH₃, 3,4-disilylhexasilane SiH₃—SiH₂—SiH(SiH₃)—SiH(SiH₃)—SiH₂—SiH₃, 2,2,3-trisilylpentasilane SiH₃—Si(SiH₃)₂—SiH(SiH₃)—SiH₂—SiH₃, 2,2,4-trisilylpentasilane SiH₃—Si(SiH₃)₂—SiH₂—SiH(SiH₃)—SiH₃, 2,3,3-trisilylpentasilane SiH₃—SiH(SiH₃)—Si(SiH₃)₂—SiH₂—SiH₃, 2,3,4-trisilylpentasilane SiH₃—SiH(SiH₃)—SiH(SiH₃)—SiH(SiH₃)—SiH₃, 2,2,3,3-tetrasilyltetrasilane SiH₃—Si(SiH₃)₂—Si(SiH₃)₂—SiH₃ and any other higher branched silanes under the general formula Si_(x)H_(2x+2) where x can be 4-20;

(c) Cyclic silanes, including; cyclotrisilane Si₃H₆, cyclotetrasilane Si₄H₈, cyclopentasilane Si₅H₁₀, cyclohexasilane Si₆H₁₀, and other cyclic silanes consisting of the general formula Si_(x)H_(2x) where x can be 3-20;

(d) Silyl substituted cyclic silanes, including; silyl cyclotetrasilane SiH3-Si₄H₇, 1,2-disilyl cyclopentasilane (SiH₃)₂—Si₅H₈, cyclohexasilane SiH₃—Si₆H₁₁, 1,3-disilyl cyclohexasilane (SiH₃)₂—Si₆H₁₀, and other silyl substituted cyclosilanes of the general formula Si_(y)H_(3y)—Si_(x)H_(2x-y) where x can be 3 to 20 and y can be 1 to 2x.

(e) Silyl substituted silanes, including; 2-tetrasilane SiH₃—SiH═SiH—SiH₃, 2,3-disilyltetrasil-2-ene SiH₃—Si(SiH₃)═Si(SiH₃)—SiH₃, 2,3-disilylpentasil-2-ene SiH₃—Si(SiH₃)═Si(SiH₃)—SiH₂—SiH₃, 2,5-disilylhexasil-2-ene SiH₃—Si(SiH₃)═SiH—SiH2—SiH(SiH₃)—SiH₃, 2,3,4-trisilylhexasil-2-ene SiH₃—Si(SiH₃)═Si(SiH₃)—SiH(SiH₃)—SiH₂—SiH₃, and other silyl substituted silanes of the general formula Si_(y)H_(3y)—Si_(x)H_(2x-(y+2))where x can be 2-20 and y can be 1 to 2x.

(f) Halogen substituted higher order silanes, including; 1,1-dichlordisilane SiHCl₂SiH₃, 1,1,1,2-tetrafluorodislane SiF₃—SiH₂F, 1,2-dichloro-1,2-difluorotetrasilane SiHClF—SiClF—SiH₂—SiH₃, 1,1,1-trichlorotrisilane SiCl₃—SiH₂—SiH₃, 1,1-difluoro-1,2,2-trichlorosilane SiF₂Cl—SiCl₂—SiH₃, chloropentasilane SiH₂Cl—(SiH₂)₃—SiH₃, and other compounds of the general formula Si_(w)H_(2w+2−z)X_(z) where X ═F, Cl, Br, I; where w can be 1 to 20 and z can be 1 to 2w+2; 2-chlorotetrasil-2-ene SiH₃-SiCl═SiH—SiH₃, 1,1-dichloro-2-fluoropentasil-2-ene SiHCl₂—SiF═SiH₂—SiH₂—SiH₃, 2,3-dichlorotetrasil-2-ene SiH₃—SiCl═SiCl—SiH₃, and other compounds of the general formula Si_(w)H_(2w-z)X′_(z) where X′ ═F, Cl, Br, I; and, w can be 2 to 20 and z can be 1 to 2w.

(g) Halogen substituted cyclic higher order silanes, including; chlorocyclopentasilane Si₅H₉Cl, dodecachlorocyclohexasilane Si₆Cl₁₂, 1-chloro-1fluorocyclopentasilane Si₅H₈FCl, and other cyclic silanes of the general formula Si_(w)H_(2w-zz)X′_(z) where X′═F, Cl, Br, I; where w can be 3 to 20 and z can be 1 to 2w.

(h) Halogen substituted silanes, including; monochlorosilane SiH₃Cl, dichlorosilane SiH₂Cl₂, trichlorosilane SiHCl₃, tetrachlorosilane (SiCl₄), and chlorodisilane SiH₃—SiH₂Cl.

(i) Halogen containing gases, including; chlorine Cl₂, hydrogen chloride HCl, chlorine trifluoride ClF₃, nitrogen trifluoride NF₃, fluorine F₂, hydrogen fluoride HF, bromine Br₂, hydrogen bromide HBr, hydrogen iodide HI and other compounds of these types.

To increase the deposition rate and improve the photoconductivity of the film, one embodiment of the present invention uses at least one additive selected from the groups (a) to (g) shown above in addition of SiH₄ and H₂; yet another embodiment of the present invention uses the combinations of additives from groups (a) to (e) and additives from groups (h) and (i) to further enhance the photoconductivity of the film.

The depositions use 5 to 10% silane; from 0.01 to 5% an additive from groups (a) to (g); 0.01 to 5% an additive from groups (h) and (i), and the rest is hydrogen, where, the flow of hydrogen, silane, an appropriate additive or additives totals 100%.

Working Examples Deposition of Amorphous Silicon Film (αSi:H)

Hydrogen plays a critical role in the properties and formation of hydrogenated silicon (Si:H) networks. Examples of this would be in the metastability of the optoelectronic properties in amorphous hydrogenated silicon which is also known as the Staebler-Wronski Effect (SWE). Another example would be in the crystallization of Si—Si bonds during microcrystalline Si:H growth.

Infrared (IR) spectroscopy is a commonly applied analytical technique used to detect the different bending, wagging, and stretching modes (SM) of hydrides in amorphous hydrogenated and microcrystalline silicon. In the bulk layer of amorphous hydrogenated silicon there are three characteristic absorptions modes; wagging modes at 640 cm⁻¹, a sClssors doublet or bending mode at 840-890 cm⁻¹ which is assigned to the di-hyrides, and the stretching modes in the range of 1895-2130 cm⁻¹. The stretching modes are of great interest due to the fact that they reflect detailed information related to the bonding environment of hydrogen in the film.

It is well understood that by using IR to analyze amorphous hydrogenated silicon for the Si—H_(x) stretching modes between 1895-2130 cm⁻¹ one can back out ratios of Si—H₂ which is also called the High Stretching Mode (HSM) at 2070-2100 cm⁻¹ and Si—H which is also call the Low Stretching Mode (LSM) at 1980-2010 cm⁻¹. Amorphous hydrogenated silicon intrinsic, layers with inferior opto-electronic properties typically are dominated by Si—H₂ stretching modes.

The Empirical Microstructure Factor (R*) is a calculation where one can back out ratios of HSM and LSM. The Empirical Microstructure Factor is defined as R*═I_(HSM)/(I_(LSM)+I_(HSM)) where I_(HSM) and I_(LSM) correspond to the integrated absorption strength of the LSM and HSM. By definition, the R* value is the percent Si—H₂ in the film. The smaller the R* value is, the less percent of Si—H₂ is in the film. In general for amorphous hydrogenated silicon to be classified as solar grade material you need R*<0.2, or less than 20%.

Plasma Enhanced Chemical Vapor Deposition (PECVD) was used in the present invention to deposit thin films of αSi:H for single junction solar cells and αSi:H and μCSi:H for tandem solar cells, using silane with hydrogen and additives.

Deposition of Amorphous Silicon Film (αSi:H)

The Empirical Microstructure Factor (R*) in amorphous hydrogenated silicon intrinsic layers produced by using Silane (SiH₄) and hydrogen can be manipulated by changing the total flow of chemical by volume and power density in a Plasma Enhanced Chemical Vapor Deposition chamber (PECVD).

Materials used to produce αSi:H and μCSi:H based solar cells include from 5 to 10% silane; from 0.9 to 1.8% of an additive or additives. Process conditions include a substrate temperature of 25°-500° C. with preferred temperatures of 150°-250° C. Process conditions include plasma powers from 10-10,000 watts, power, densities from 019 W/cm² to 1.6 W/cm² and chamber pressures from 0.01 torr to 15 torr.

FIG. 1 was a graph showing the Empirical Microstructure Factor R* of hydrogenated silicon αSi:H deposited versus SiH₄ flow rate under different power densities. The percentage of SiH₄ used was 9.0% and H₂ was 91%.

The flow rate of the SiH₄ ranged from 0 to 125 sccm; and the power densities were at 0.197, 0.789, 1.382 and 1.58 W/cm².

As the power density increased at lower flow rate range (see the flow rates <50 sccm), the Empirical Microstructure Factors R* tended to be above 20% for all power densities. As the flow rate increased>50 sccm, as power density increased, the Empirical Microstructure Factors R* started to decrease for all power densities, except for 0.197 W/cm². However, it's interesting to point out that the Empirical Microstructure Factors R* did not get below 20% at higher flow rates (100 and 125 sccm) for all power densities, except at 0.789 W/cm², which led to the conclusion that these films would not produce a suitable solar grade material.

The added value of produClng the Empirical Microstructure Factors R* below 20% at high power densities and high flow rates was the benefit of increased growth rates of the intrinsic films.

FIG. 2 was a graph showing the deposition (growth) rate versus SiH₄ flow rate under different power densities. The Empirical Microstructure Factor R* for the data was at 10%. The percentage of SiH₄ used was 9.0% and H₂ was 91%. The flow rate of the SiH₄ ranged from 0 to 125 sccm; and the power densities were at 0.197, 0.394, 0.592, 0.789, 0.987, 1.184, 1.382 and 1.58 W/cm².

FIG. 2 showed that as flow rates and power densities increased, the deposition rates also increased.

Disilane was used as the at least one of additives for higher order silanes shown above in group (a). The disilane used ranged from 0.9% to 1.8%.

The deposition rate versus the flow rate of the mixture of silane with disilane under different power densities had been shown in FIG. 3. The percentage of disilane was 0.9%, silane was 8.1%, and hydrogen was 91%.

The flow rate of the mixture of SiH₄ and disilane ranged from 0 to 125 sccm; and the power densities were at 0.197, 0.394, 0.592, 0.789, 0.987, 1.184, 1.382 and 1.58 W/cm².

By using at least one of these higher order silanes as an additive to silane in the deposition process, the amorphous phase deposition (growth) rate significantly increased as the flow rate increased at all power densities compared to the neat silane films shown in FIG. 2.

FIG. 4 illustrated Empirical Microstructure Factor R* as a function of the flow rate of mixture of silane with trisilane at different power densities, the trisilane was used as at least one additive. The percentage of Trisilane was 0.9%, Silane was at 8.1%, and Hydrogen was at 91%. The flow rate of the mixture of SiH₄ and trisilane ranged from 0 to 125 sccm; and the power densities were at 0.197, 0.394, 0.592, 0.789, 0.987, 1.184, 1.382 and 1.58 W/cm².

FIG. 4 has shown that as the flow rates of the mixture of silane and trisilane increased, R* value, that is, the % of Si—H₂ in the film decreased to less than 20% for all power densities greater than and equal to 0.789 W/cm². This gave the add benefit of the increased growth rate with the Empirical Microstructure Factor R* below 20% to produce a suitable solar grade material.

However, the R* values did not reach <20% for the power densities less than and equal to 0.5923 W/cm². This indicated that these films would not be a suitable solar grade material.

Thus, to deposit a suitable solar grade silicon film, both the Empirical Microstructure Factor R* value and the deposition rate are important factors.

As shown above in FIG. 4, although the deposition rates were higher at power densities less than and equal to 0.5923 W/cm² (comparing with the data shown in FIG. 2—no disilane used), however, due to the higher R* values (>20%), no suitable solar grade films can be deposited with trisilane as an additive at those power densities.

Deposition of Microcrystalline Silicon Film (μCSi:H)

The dual benefit of faster deposition and higher photoconductance can be achieved through the use of dual functional additives designed to incorporate the chemical features required to achieve both types of process enhancement.

The growth rate enhancement and photoconductivity maintaining are achieved through addition of at least one higher order silane from groups (a) to (e), while by incorporating at least one additional moiety from groups (h) and (i), such as a halogen, on the silane or, higher order silane, microcrystalline fraction is increased and the impact of film defects and impurities is reduced.

For example, molecules such as monchlorosilane (SiH₃Cl or MCS), dichlorosilane (SiH₂Cl₂), chlorodisilane (Si₂H₅Cl₂) can be used as the at least one additional additives, in addition to growth rate enhanClng higher order silane, such as disilane and trisilane to the process yielding higher fractions of microcrystalinity in the deposited film.

PECVD process is used in depositing the microcrystalline silicon film (μCSi:H).

For the data obtained in FIG. 5, monchlorosilane (SiH₃Cl) is used as the at least one additional additive, the higher order silanes are represented by Si_(x)H_(y), wherein x=2 to 20 and y═6 to 42.

The mixture of the halogenated silane SiH₃Cl with silane (SiH₄) and, higher order silanes (Si_(x)H_(y)) is represented by (SiH₃Cl+Si_(x)H_(y)), wherein x═2 to 20 and y═6 to 42. The mole fraction SiH₃Cl/(SiH₃Cl+Si_(x)H_(y)) % is the ratio of the halogenated silane SiH₃Cl (MCS) to the mixture of the halogenated silane SiH₃Cl with silane (SiH₄) and higher order silanes (Si_(x)H_(y)).

The flow rate of H₂ ranges from 91 to 99%, the flow rate of the mixture ranges from 1% to 9%. The preferred embodiment of the example is (SiH₃Cl+Si_(x)H_(y)) flows of 1-2% and H₂ flows of 98-99% based on the reactor plasma frequency of 13.56 MHz.

Those skilled in the art will realize that higher plasma frequenCles, such as 40.68 MHz, will permit higher, relative (SiH₃Cl+Si_(x)H_(y)) flows.

The film deposition in FIG. 5 is performed at 13.56 MHz using 1-9% silane, 1-9% higher order silane, and 1-9% SiH₃Cl, with total Si containing moieties not exceeding 9% ((SiH₄+SiH₃Cl+Si_(x)H_(y))<or equal 9%). The preferred embodiment of the present example is to use 1-2% silane, 0.1-0.2% higher order silane (Si_(x)H_(y)), 0.1-0.2% MCS, and with balance being hydrogen.

FIG. 5 shows the results of the change of the microcrystalline fraction as the function of the mole fraction of SiH₃Cl/(SiH₃Cl+Si_(x)H_(y)) %. Applicants have found that all the higher order silanes functioned the same.

When no SiH₃Cl is added, the Microcrystalline fraction is around 38%. The microcrystalline fraction reaches an optimum value about 51% at approximately 0.18 mole fraction of SiH₃Cl/(SiH₃Cl+Si_(x)H_(y)) %, and trends down until the film becomes amorphous at >0.5 mole fraction. An optimal amount of Cl added to the deposition aids in the nucleation process for microcrystalline formation. As more Cl is added the film trends towards the amorphous phase. The speClfic mechanisms yielding optimized microcrystalline fractions at a given Cl partial pressure in the plasma are not fully understood but are suspected of being related to Cl aiding in the microcrystalline seeding process. Excess Cl disrupts the structured deposition of microcrystalline yielding higher degrees of amorphous silicon fractions within the deposited film.

FIG. 5 clearly indicates that the use of halogen substituted silanes in addition of higher order silanes will increase the microcrystalline fraction, providing an optimal band gap for the microcrystalline layer of 1.2 eV as part of the tandem solar cell.

The film deposition conditions used in FIG. 6 are the same as in FIG. 5.

FIG. 6 shows the dark current activation energy versus the mole fractions of halogenated silanes SiH₃Cl/(SiH₃Cl+Si_(x)H_(y)) %, wherein Si_(x)H_(y)═SiH₄+Si_(x)H_(y) wherein x=2-20 and y═6-42. The dark current activation energy is the energy required to generate charge carriers in the absence of light for deposited microcrystalline

As demonstrated in FIG. 6, the dark current activation energy (E_(ACT)) is impacted by the addition of chlorine to the process. The effect of chlorine addition increases dark current E_(ACT) from 0.2 eV to approximately 0.6 eV indicating that the effects of chlorine addition are reduction of the effects of donor impurities such as oxygen on the deposited microcrystalline film at low mole fractions from 0.10 to 0.40 of halogenated silanes SiH₃Cl/(SiH₃Cl+Si_(x)H_(y)) %, compared to the absence of added chlorine.

As shown in FIG. 6, at high chlorine mole fractions>0.5, E_(ACT) increases as the film transitions from microcrystalline to amorphous phase.

Those results are believed to be attributed to Cl acting as an impurity scavenger reduClng the doping capaClty, of impurities. The enhancement in photoconductivity is realized by shifting the Fermi level to mid band gap for the enhanced growth rate intrinsic microcrystalline film.

The shift in Fermi level to the middle of the band gap at ca. 0.6 eV provides the optimal electrical bias for, a p-i-n type photovoltaic device that is the subject of this invention. The electrical bias inherent to the p-i-n structure aids in separation of charge carriers created in the intrinsic Si layer thus leading to higher degree of current extraction and higher degree of solar cell effiClency. The use of the appropriate quantity of halogen during deposition, from 0.1 to 0.4 mole fraction of the silane containing moieties, yields a film that is less impacted from the defects, such as impurity incorporation, that can occur during higher deposition rates.

Figures 5 and 6 have demonstrated that the use of higher order silanes and Halogen substituted silanes will increase the deposition rate, the microcrystalline fraction, and enhance the photoconductivity of the film. The present invention has demonstrated that the de position of αSi:H and μCSi:H at deposition rates 2-20 times higher than industry averages reported above. These include deposition rates for αSi:H of 10-200 Å/sec and for μCSi:H of 2-100 Å/sec.

The deposited αSi:H films for formation of single junction solar cells had effiClenCles of 5-15%. The deposited αSi:H and μCSi:H films for forming tandem junction solar cells had effiClenCles of 7-20%. Solar cell effiClency is defined as: Solar cell effiClency (%)═(Power out (W)×100%)/(Area (m²)×1000 W/m²). These effiClency improvements were the result from the addition of additives to the deposited films yielding enhanced photoconductivity.

The foregoing examples and description of the embodiments should be taken as illustrating, rather than as limiting the present invention as defined by the claims. As will be readily appreClated, numerous variations and combinations of the features set forth above can be utilized without departing from the present invention as set forth in the claims. Such variations are intended to be included within the scope of the following claims. 

The invention claimed is;
 1. A method of deposition for a solar grade amorphous silicon film (αSi:H) as a photoconductive film on a substrate, using Silane; hydrogen; and at least one additive selected from the group consisting of: (a) higher order straight chain silanes, comprising; disilane Si₂H₆, trisilane Si₃H₈, tetrasilane Si₄H₁₀, pentasilane Si₅H₁₂,hexasilane Si₆H₁₄, heptasilane Si₇H₁₆, octasilane Si₈H₁₈, nonasilane Si₉H₂₀, decasilane Si₁₀H₂₂ and mixtures thereof; (b) higher order branched silanes, comprising; 2-silyl-trisilane SiH₃—Si(H)(SiH₃)—SiH₃, 2,2-disilyl-trisilane SiH₃—Si(SiH₃)₂—SiH₃, 2-silyl-tetrasilane SiH₃—Si(H)(SiH₃)—SiH₂—SiH₃, 2,3-disilyltetrasilane SiH₃—SiH(SiH₃)—SiH(SiH₃)—SiH₃, 2,2-disilyltetrasilane SiH₃—Si(SiH₃)₂—SiH₂—SiH₃, 3-silylpentasilane SiH₃—SiH₂—SiH(SiH₃)—SiH₂—SiH₃, 2-silylpentasilane SiH₃—SiH(SiH₃)—SiH₂—SiH₂—SiH₃, 2,3-disilylpentasilane SiH₃—SiH(SiH₃)—SiH(SiH₃)—SiH₂—SiH₃, 2,4disilylpentasilane SiH₃—SiH(SiH₃)—SiH₂—SiH(SiH₃)—SiH₃, 2-silylhexasilane SiH₃—SiH(SiH₃)—(SiH₂)₃SiH₃, 3-silylhexasilane SiH₃—SiH₂—SiH(SiH₃)—(SiH₂)₂SiH₃, 2,2disilylpentasilane SiH₃—Si(SiH₃)₂—(SiH₂)₂—SiH₃, 3,3-disilylpentasilane SiH₃—SiH₂Si (SiH₃)₂—SiH₂ —SiH₃, 2,2,3-trisilyltetrasilane SiH₃—Si(SiH₃)₂—SiH(SiH₃)—SiH₃, 2silylheptasilane SiH₃—SiH(SiH₃)—(SiH₂)₄—SiH₃, 3-silylheptasilane SiH₃—SiH₂—SiH(SiH₃)—(SiH₂)₃—SiH₃, 4-silylheptasilane SiH₃—(SiH₂)₂—SiH(SiH₃)—(SiH₂)₂—SiH₃, 2,2-disilylhexasilane SiH₃—Si(SiH₃)₂—(SiH₂)₃—SiH₃, 2,3-disilylhexasilane SiH₃—SiH(SiH₃) —SiH(SiH₃)—(SiH₂)₂—SiH₃, 2,4-disilylhexasilane SiH₃—SiH(SiH₃)—SiH₂—SiH(SiH₃)—SiH₂—SiH₃, 2,5-disilylhexasilane SiH₃—SiH(SiH₃)—(SiH₂)₂—SiH(SiH₃) SiH₃, 3,3-disilylhexasilane SiH₃—SiH₂—Si(SiH₃)₂—(SiH₂)₂—SiH₃, 3,4disilylhexasilane SiH₃—SiH₂—SiH(SiH₃)—SiH(SiH₃)—SiH₂—SiH₃, 2,2,3trisilylpentasilane SiH₃—Si(SiH₃)₂—SiH(SiH₃)—SiH₂—SiH₃, 2,2,4-trisilylpentasilane SiH₃—Si(SiH₃)₂—SiH₂—SiH(SiH₃)—SiH₃, 2,3,3-trisilylpentasilane SiH₃—SiH(SiH₃)—Si(SiH₃)₂—SiH₂—SiH₃, 2,3,4-trisilylpentasilane SiH₃—SiH(SiH₃)—SiH(SiH₃)—SiH(SiH₃)—SiH₃, 2,2,3,3-tetrasilyltetrasilane SiH₃—Si(SiH₃)₂—Si(SiH₃)₂—SiH₃ and mixtures thereof; (c) cyclic silanes, selected from the group consisting of; cyclotrisilane Si₃H₆ cyclotetrasilane Si₄H₈, cyclopentasilane Si₅H₁₀, cyclohexasilane Si₆H₁₀, and mixtures thereof; (d) silyl substituted cyclic silanes, selected from the group consisting of; silyl cyclotetrasilane SiH3—Si₄H₇, 1,2-disilylcyclopentasilane (SiH₃)₂—Si₅H₈, silyl cyclohexasilane SiH₃—Si₆H₁₁, 1,3-disilylcyclohexasilane (SiH₃)₂—Si₆H₁₀, and mixtures thereof; (e) silyl substituted silanes, selected from the group consisting of; 2-tetrasilane SiH₃—SiH═SiH—SiH₃, 2,3-disilyltetrasil-2-ene SiH₃—Si(SiH₃)═Si(SiH₃)—SiH₃, 2,3disilylpentasil-2-ene SiH₃—Si(SiH₃)═Si(SiH₃)—SiH₂—SiH₃, 2,5-disilylhexasil-2-ene SiH₃—Si(SiH₃)═SiH—SiH2—SiH(SiH₃)—SiH₃, 2,3,4-trisilylhexasil-2-ene SiH₃—Si(SiH₃)═Si(SiH₃)—SiH(SiH₃)—SiH₂—SiH₃, and mixtures thereof; (f) halogen substituted silanes, including; 1,1-dichlordisilane SiHCl₂SiH₃, 1,1,1,2-tetrafluorodislane SiF₃—SiH₂F, 1,2-dichloro-1,2-difluorotetrasilane SiHCIF—SiCIF—SiH₂—SiH₃, 1,1,1-trichlorotrisilane SiCl₃—SiH₂—SiH₃, 1,1-difluoro1,2,2-trichlorosilane SiF₂Cl—SiCl₂—SiH₃, chloropentasilane SiH₂Cl—(SiH₂)₃—SiH₃, and other compounds of the general formula Si_(w)H_(2w+2−z)X_(z) where X ═F, Cl, Br, 1; w can be 1 to 20 and z can be 1 to 2w+2; 2-chlorotetrasil-2-ene SiH₃—SiCl═SiH—SiH₃, 1,1-dichloro-2-fluoropentasil-2-ene SiHCl₂—SiF═SiH₂—SiH₂—SiH₃, 2,3-dichlorotetrasil-2-ene SiH₃—SiCl═SiCl—SiH₃, and other compounds of the general formula Si_(w)H_(2w−)X′_(z) where X′═F, Cl, Br, I; and, w can be 2 to 20 and z can be 1 to 2w; and mixtures thereof; and (g) halogen substituted cyclic silanes, selected from the group consisting of; chlorocyclopentasilane Si₅H₉Cl, dodecachlorocyclohexasilane Si₆Cl₁₂, 1chloro-1fluorocyclopentasilane Si₅H₈FCl, and mixtures thereof; wherein the silane used is at 5 to 10%, and the at least one additive used is at 0.01 to 5%, and the rest is hydrogen .
 2. The method of deposition for the solar grade amorphous silicon film (αSi:H) of claim 1, wherein the deposition is performed at a substrate temperature of 25°-500° C., and pressure of 0.01 torr to 15 torr.
 3. The method of deposition for the solar grade amorphous silicon film (αSi:H) of claim 2, wherein the substrate temperature is at 150°-250° C.
 4. The method of deposition for the solar grade amorphous silicon film (αSi:H) of claim 1, wherein the deposition is a process selected from the group consisting of Chemical Vapor Deposition (CVD), Plasma Enhanced Chemical Vapor Deposition (PECVD), Low Pressure Chemical Vapor Deposition (LPCVD), Hot Wire Chemical Vapor Deposition (HWCVD), Initiated Chemical Vapor Deposition (ICVD) and Sub Atmospheric Chemical Vapor Deposition (SA-CVD).
 5. The method of deposition for the solar grade amorphous silicon film (αSi:H) of claim 1, wherein the deposition is a plasma enhanced chemical vapor deposition at a plasma power density ranging from 0.19 -1.6W/cm² and a plasma frequency ranging from 13.56 to 40.68 MHz.
 6. The method of deposition for the solar grade amorphous silicon film (αSi:H) of claim 5 having a deposition rate ranging from 10 - 200 Å/sec.
 7. The method of deposition for the solar grade amorphous silicon film (αSi:H) of claim 5, wherein a deposited film provides a single junction solar cell having efficiencies of 5 -15%; and a tandem junction solar cell having efficiencies of 7 - 20%.
 8. A method of deposition for a solar grade amorphous silicon film (αSi:H) or a microcrystalline silicon film (μCSi:H) having high microcrystalline fraction as a photoconductive film on a substrate, using Silane; hydrogen; and at least one additive selected from the group consisting of: (a) halogen substituted higher order silanes, including; 1,1-dichlordisilane SiHCl₂SiH₃, 1,1,1,2-tetrafluorodislane SiF₃—SiH₂F, 1,2-dichloro-1,2difluorotetrasilane SiHCIF—SiCIF—SiH₂—SiH₃, 1,1,1-trichlorotrisilane SiCI₃—SiH₂—SiH₃, 1,1-difluoro-1,2,2-trichlorosilane SiF₂Cl—SiCl₂—SiH₃, chloropentasilane SiH₂Cl—(SiH₂)₃—SiH₃, and other compounds of the general formula Si_(w)H_(2w+2−z)X_(z) where X ═F, Cl, Br, I; w can be 1 to 20 and z can be 1 to 2w+2; 2chlorotetrasil-2-ene SiH₃—SiCl═SiH—SiH₃, 1,1-dichloro-2-fluoropentasil-2-ene SiHCl₂—SiF═SiH₂—SiH₂—SiH₃, 2,3-dichlorotetrasil-2-ene SiH₃—SiCl═SiCl—SiH₃, and other compounds of the general formula Si_(w)H_(2w−z) X′_(z) where X′═F, Cl, Br, I; and, w can be 2 to 20 and z can be 1 to 2w; and mixtures thereof; and (b) halogen substituted cyclic higher order silanes, selected from the group consisting of; chlorocyclopentasilane Si₅H₉Cl, dodecachlorocyclohexasilane Si₆Cl₁₂, 1-chloro-1fluorocyclopentasilane Si₅H₈FCl, and mixtures thereof.
 9. The method of deposition for the solar grade amorphous silicon film (αSi:H) or the microcrystalline silicon film (μCSi:H) having high microcrystalline fraction of claim 8, wherein the silane used is at 5 to 10%, and the at least one additive used is at 0.01 to 5%, and the rest is hydrogen.
 10. The method of deposition for the solar grade amorphous silicon film (αSi:H) or the microcrystalline silicon film (μCSi:H) having high microcrystalline fraction of claim 8, wherein the deposition is a process selected from the group consisting of Chemical Vapor Deposition (CVD), Plasma Enhanced Chemical Vapor Deposition (PECVD), Low Pressure Chemical Vapor Deposition (LPCVD), Hot Wire Chemical Vapor Deposition (HWCVD), Initiated Chemical Vapor Deposition (ICVD) and Sub Atmospheric Chemical Vapor Deposition (SA-CVD).
 11. The method of deposition for the solar grade amorphous silicon film (αSi:H) or the microcrystalline silicon film (μCSi:H) having high microcrystalline fraction of claim 8, wherein the deposition is a plasma enhanced chemical vapor deposition at a plasma power density ranging from 0.19 -1.6 W/cm² and a plasma frequency ranging from 13.56 to 40.68 MHz.
 12. The method of deposition for the solar grade amorphous silicon film (αSi:H) or the microcrystalline silicon film (μCSi:H) having high microcrystalline fraction of claim 11, having a deposition rate of 10 - 200Å/sec for amorphous silicon film (αSi:H) and 10 - 100 Å/sec for microcrystalline silicon film (μCSi:H).
 13. The method of deposition for the solar grade amorphous silicon film (αSi:H) or the microcrystalline silicon film (μCSi:H) having high microcrystalline fraction of claim 11, wherein the deposited amorphous silicon film (αSi:H) provides a single junction solar cell having efficiencies of 5 -15%; and the deposited amorphous silicon film (αSi:H) or microcrystalline silicon film (μCSi:H) provides a tandem junction solar cell having efficiencies of 7 - 20%. 